Electronic blind and method for manufacturing electronic blind

ABSTRACT

The embodiment discloses an electronic blind and method for manufacturing electronic blind, for the whole or partial area light control management. An electronic blind that comprises a pair of substrates, polymer/liquid crystal composite material sandwiched between the pair of substrates, and a pair of electrodes formed on an opposing surface of the pair of substrates, one electrode of the pair of electrodes being patterned over one substrate in line form at intervals from one side to the other side of the substrate, other electrode of the pair of electrodes being formed over whole the surface of another substrate.

TECHNICAL FIELD

This invention discloses the electronic blind and method for manufacturing electronic blind. In more detail, the invention discloses electronic blind and method for manufacturing electronic blind, for the whole or partial area light control management of window etc. of the building.

BACKGROUND OF THE INVENTION

Usually, liquid crystal panel is fabricated by sandwiching polymer/liquid crystal composite material having polymer domains and liquid crystal domain between a pair of transparent plastic substrates (referred as substrate), where opposite inward surface of substrates are coated with transparent electrically conductive film of indium tin oxide (ITO). Normally, polymer/liquid crystal composite material is coated on substrate, irradiated by UV light and sandwiched between pair of substrates to form phase separated milky white state. When certain voltage of an AC field is applied across the substrates, polymer/liquid crystal composite material is influenced by applied voltage and liquid crystal rotate & align along the field to allow the light to pass to be transparent, when AC voltage is off light does not pass to have opaque state.

Various types of liquid crystal panels as mentioned above are recommended (for example Patent Document 1). FIG. 6 is the schematic diagram of existing liquid crystal panel. In FIG. 6, phase separated polymer/liquid crystal composite layer 101, consists of two types of polymer materials and liquid crystal material, confined between transparent electrodes 102 and 103 of the liquid crystal panel. Where, transparent electrodes 102 and 103 is made of transparent conducting layer 102B and 103B over respective base transparent film 102A and 103A. Transparent conducting layer 102B and 103B is in contact of polymer/liquid crystal composite layer 101. When, AC voltage 104 is applied across transparent electrodes 102 and 103, light passes through polymer/liquid crystal composite layer 101 and when AC voltage is off light dose not pass through.

Patent Document 1: JP5-45634(A)

DISCLOSURE OF THE INVENTION Problems to be Solved by the Invention

The present liquid crystal panel, could control the light over whole area only, has uniform transparent electrode, however light control over partial area moreover in slat form was not available.

Also liquid crystal panels each with transparent electrode placed adjacent between upper and lower substrates could be thought off however, polymer/liquid crystal composite in the liquid crystal panel is required to be sealed using sealing material. In this case, electrical connection technique become complex, cost involving and production of finished product become expensive. Apart from that sealing space between adjacent liquid crystal panels becomes wide making opaque area larger between liquid crystal panels.

The present invention addresses all the above mention issues involved so far. The purpose of the present invention is to disclose the electronic blind and method for manufacturing electronic blind for light control management over whole or partial area.

Means of Solving the Problems

In the embodiment of the invention, the disclosed electronic blind consists of, a pair of substrates, polymer/liquid crystal composite material sandwich between said pair of substrates and a pair of electrodes for electronic blind. Out of pair of electrodes, one electrode is patterned from one side to the other side of substrate in line form at intervals, while other electrode is formed uniformly over another substrate.

Since, one substrate has patterned electrode from one side of the substrate to the other side of substrate in line form at intervals voltage can be applied over partial area. Also, since one substrate has patterned electrode and another substrate has uniform electrode, there is no need to adjust the upper and lower opposite electrodes.

Also, electronic blind as disclosed in this invention, the scattering zone becomes thin and whole area looks transparent, when patterned line electrode width is 0.66 mm or less, or 0.2 mm or less.

Also, electronic blind as disclosed in the in embodiment, the polymer/liquid crystal composite material is composed of 2-Ethyl hexyl acrylate, 1-6-Hexadianol di acrylate, oligomer & poly-acrylate mixture or at least one of them in the composition and the rest is the liquid crystal. 2-Ethyl hexyl acrylate in composition leads to the low voltage drive of electronic blind and 1-6 Hexadianol di acrylate leads to fast response time, while oligomer & poly-acrylate mixture or at least one of them could increase the viscosity of polymer/liquid crystal composition.

To achieve the objective of invention, the manufacturing process of electronic blind consists of, the process of forming electrodes on the surface of a pair of substrates, the process of sandwiching the polymer/liquid crystal composite for manufacturing electronic blind by placing the polymer/liquid crystal material between pair of substrates, the process of forming a pair of electrodes on the opposite surface of a pair of substrates where one electrode is patterned from one side to the other side of substrate in line form at intervals, while other electrode is formed uniformly over another substrate.

Electronic blind, where voltage can be applied over partial area, could be manufacture by process of patterning electrode at intervals from one side of the substrate to the other side of substrate in line form. Also, by process of forming uniform electrode over other substrate, an electronic blind that does not require of adjustment upper and lower opposite electrodes can be manufactured.

Also, the manufacturing process for electronic blind as disclosed in this invention, the scattering zone becomes thin and whole area looks transparent, when patterned electrode is formed at interval 0.66 mm or less, or 0.2 mm or less.

Manufacturing process of electronic blind as disclosed in the in embodiment, the polymer/liquid crystal composite material is composed of 2-Ethyl hexyl acrylate, 1-6 Hexadianol di acrylate, oligomer & poly-acrylate mixture or at least one of them in the composition and the rest is the liquid crystal. 2-Ethyl Hexyl Acrylate in composition leads to low voltage operation of electronic blind and 1-6 Hexadianol Di Acrylate leads to the fast response time, while oligomer & poly-acrylate mixture or at least one of them could increase the viscosity of polymer/liquid crystal composition.

EFFECT OF THE INVENTION

The electronic blind as disclosed in the present invention could control the light over whole area or selective partial area.

The method of manufacturing electronic blind as disclosed in the present invention enables the fabrication of electronic blind that can control the passage of light over whole or selective partial area.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1( a) shows Polyethylene terephthalate (ITO-PET) film with uniform film of ITO on one surface. FIG. 1( b) shows the roll of ITO-PET film with horizontal pattern of ITO from one side to the other side in line form separated from each other at intervals.

FIG. 2 shows the example of manufacturing process of electronic blind panel by roll to sheet coating process.

FIG. 3( a) shows the side view of electronic blind panel. FIG. 3( b) shows the front view of electronic blind panel. FIG. 3( c) shows the cross sectional view of electronic blind panel.

FIG. 4( a) shows the schematic of contact electrode for 1st substrate. FIG. 4( b) shows the schematic for individual segment contact ITO electrode for patterned 2nd substrate. FIG. 4( c) shows the schematic of electronic blind made from 1st film substrate with contact electrode & 2nd film substrate with each ITO layer has contact electrode.

FIG. 5( a) shows the schematic as an example when individual segment of electronic blind is switched to clear transparent state on application of electric field. FIG. 5( b) shows the schematic as an example when the plurality of the segments of electronic blind switched to clear transparent state on application of electric field. FIG. 5( c) shows the schematic of electronic blind when all the segments are switched to clear transparent state on application of electric field.

DESCRIPTION OF REFERENCE NUMERALS

-   -   1 1st Film Substrate     -   2 2nd Film Substrate     -   3 1st Transparent electrode layer     -   4 2nd Transparent electrode layer     -   4A ITO Layer     -   4B Layer without ITO     -   5 Polymer/Liquid crystal composite material     -   6 Coating process     -   7 Roller     -   7A Roller rotation direction     -   8 UV irradiation process     -   9 Electronic blind panel     -   10 Length of electronic blind panel     -   11 Width of electronic blind panel     -   12 Copper foil electrode     -   13 Connector electrode

BEST MODE FOR CARRYING OUT THE INVENTION

As mention below, using the description of figures, the contents of the invention is described as follow. The light control using patterned electrode, as well as electronic blind and manufacturing process of electronic blind, that can be used for architecture building materials and automotive application is described.

The material for substrate (film substrate), which could be used for the electronic blind as disclosed in the invention, could be polyethylene terephthalate (PET film), polyethylene naphthalate (PEN film) or film like polycarbonate (PC). The substrate films as mentioned above are coated with indium tin oxide ITO to form clear transparent conducting electrode layer.

Next, in polymer/liquid crystal composition used for the electronic blind as disclosed in the invention spacer as micro-sphere is mixed in certain ratio so as to fix the uniform thickness of the polymer/liquid crystal composition. Later, polymer/liquid crystal composition could be coated on the substrate using multi-coating or curtain coating or screen-printing. Next, boundary of the substrate is sealed using sealing material to prevent the entry of oxygen and moisture that can cause degradation of polymer/liquid crystal composite and UV irradiation is done to cure the monomers to form the phase separated composite film.

Polymer/liquid crystal composition used for the electronic blind as disclosed in the invention, is composed of mixture of acrylate monomers, while oligomer or poly-acrylate mixture could increase the viscosity of polymer/liquid crystal composition. Moreover, for speed up the rate of polymerization a photo-curing initiator such as 2-dimethoxy-2-phenyl acetophenone is added to the composition.

The liquid crystal used for the electronic blind as disclosed in the invention is the mixture of biphenyl, cyclohexane and fluorine-containing liquid crystal. A mixture of liquid crystals has been chosen taking care of temperature range as well as birefringence and viscosity in consideration. The low birefringence liquid crystal (Δn=0.18) in polymer/liquid crystal composition is chosen purposefully to tailor the desired properties such as low haze. Since, the liquid crystal used dissolves in the monomer which forms a clear solution in homogeneity, the viscosity of the homogeneous mixture of liquid crystal and monomers has been fixed in range of 50 to 250 Cps (50 to 250 mPa·s) taking care of roll to sheet coating process on plastic film. When liquid crystal viscosity is less than 50 mPa·s, the adhesion to the substrate is weak and easy to peel off making it not suitable while in case of liquid crystal viscosity more than 250 mPa·s, liquid crystal becomes too viscous and is not suitable to use.

In Polymer/liquid crystal composition the ratio of liquid crystal is 70 to 82 weight % and pre-polymer ratio is 30 to 18 weight %. If ratio of liquid crystal is large in composition it results in lower drive voltage but low contrast whereas increase in ratio of pre-polymers in composition leads to higher driving voltage, higher haze and low viscosity.

The pre-polymer composition is mixture of mono acrylate, diacrylate and polyacrylate or oligomers or at least one of them and their ratio in pre-polymer composition influences the electro-optical performance of the composite. Increase in ratio of mono-acrylate in composition leads to low drive voltage whereas increasing ratio of diacrylate leads to higher driving voltage and fast switching time. Monoacrylate & oligomer influence the viscosity of the polymer/liquid crystal composition. The addition of poly-acrylate or oligomers in the composition leads in increase of viscosity.

Polymer/liquid crystal composite as disclosed in this invention is mixture of acrylate monomers and oligomer where viscosity of polymer/liquid crystal composition could be tailored as desired. Also, polymer/liquid crystal composite as disclosed in this invention has following merits such as low price, high contrast and low haze.

Example 1

An example is de scribed below for more specific description Polymer/liquid crystal composite. The total weight percent of polymer/liquid crystal composition is composed of 2 ethylhexyl acrylate (Aldrich Co., Ltd.) 6 weight % and M-1210 (product name, acrylate oligomer, Toagosei Co., Ltd) 12.0 weight % and 1-6 hexadianol di acrylate (Aldrich Co., Ltd.) 2.0 weight % and liquid crystal TEB 50 (product name, Shijiazhuang Slichem Liquid Crystal Materials Co. Ltd.) 80.0 weight %. Next, 2-dimethoxy-2-phenyl acetophenone a photo-initiator 5 weight % was added to the composition respective to the total weight fraction of monomers 2-ethyl hexyl acrylate, M-1210 and 1-6 hexadianol di acrylate. Polymer/liquid crystal composition was coated on a transparent conducting glass substrate and covered with another transparent conducting glass substrate so as to keep polymer/liquid crystal composite thickness 16 μm. Next, test cell of thickness 16 μm was prepared by curing the polymer/liquid crystal composite by UV irradiation at 30 mW/cm² over the substrate for 30 sec. at 20° C. (degree centigrade). The electro-optical properties of the polymer/liquid crystal composite material measured at 25° C. (degree centigrade) are shown as Example 1 in Table 1.

Example 2

An example is described be low for more specific description Polymer/liquid crystal composite. The total weight percent of polymer/liquid crystal composition is composed of 2 ethyl hexyl acrylate (Aldrich Co., Ltd.) 6 weight % and M-1210 (product name, Acrylate Oligomer, Toagosei Co., Ltd) 12.0 weight % and 1-6 hexadianol di acrylate (Aldrich Co., Ltd.) 2.0 weight % and liquid crystal TEB-300 (product name, birefringence 0.18, Shijiazhuang Slichem Liquid Crystal Materials Co. Ltd.) 80.0 weight %. 2-dimethoxy-2-phenyl acetophenone a photo-initiator 5 weight % was added to the composition respective to the total weight fraction of monomers 2 ethyl hexyl acrylate, M-1210 and 1-6 hexadianol di acrylate. Next, test cell of thickness 16 μm was prepared by curing the polymer/liquid crystal composite by UV irradiation at 30 mW/cm² over the substrate for 30 sec. at 20° C. (degree centigrade). The electro-optical properties of the polymer/liquid crystal composite material measured at 25° C. (degree centigrade) are shown as Example 2 in Table 1.

TABLE 1 Example 1 Example 2 Transmittance 0.89 1.25 (Voltage off) (%) Transmittance 86.54 86.00 (Voltage on) (%) Voltage at 6.1 5.9 Transmittance 10% (V) Voltage at 10.8 10.6 Transmittance 90% (V) Hystersis (V) 1.5 1.6 Rise Time (ms) 0.39 0.43 Decay Time (ms) 14.87 44.92 Viscosity (at 68 210 20° C.) (mPa · s)

FIG. 1( a) shows Polyethylene terephthalate (ITO-PET) film with uniform film of ITO on one surface. FIG. 1( b) shows the roll of ITO-PET film with horizontal pattern of ITO from one side to the other side in line form separated from each other at intervals.

As shown in FIG. 1( a) the transparent conductive electrode layer 3 is uniform film of ITO formed over one surface of 1st film substrate 1 that is made of PET film. As shown in FIG. 1( b) electrode 4 is ITO layer pattern along the width over the 2nd film substrate 2 where 4A is the ITO layer and 4B is space without ITO layer. The electrode 4 over 2nd film substrate 2 mentioned above could be used in place manufactured by Tobi Co., Ltd. where, ITO layer 4A has width space 40 mm and without ITO layer 4B has width space 0.5 mm. Also ITO layer 4A is separated at interval by without ITO layer space.

In case of ITO layer patterned at certain intervals, the ITO layer width is not necessary to be 40 mm, also without ITO space width may not be exact 0.5 mm but it could be 0.66 mm or less, or 0.2 mm or less, or even 0.3 mm is also feasible. Also, In case of ITO layer patterned at certain intervals, the patterning could be done along the width of 2nd substrate or along the length of 2nd substrate.

The thickness of 1st film substrate or 2nd film substrate is usually 125 μm, however it could be chosen as 175 μm or 188 μm depending on ITO coating process.

FIG. 2 shows the schematic of an example of manufacturing process of electronic blind panel by roll to sheet process. The 1st film substrate having uniform transparent electrode made of ITO layer on its one surface and 2nd film substrate having transparent electrode on its one surface with interval of ITO layer separated by space without ITO layer are unwind from their respective rolls. Also, micro-sphere called as spacer is mixed with polymer/liquid crystal composition 5 to maintain the uniform thickness of the composition throughout.

Next, as of coating process 6 polymer/liquid crystal composite material 5 is coated over 1st film substrate having uniform transparent electrode made of ITO layer on its one surface. Next, polymer/liquid crystal composite 5 is laminated by 2nd substrate with electrode surface facing the polymer/liquid crystal composite material. Thus using the unwinding direction 7A of roller 7, polymer/liquid crystal composite 5 is laminated within 1st film substrate 1 and 2nd film substrate 2. Next at 25° C. (degree centigrade), 30 mW/cm² for 30 sec. UV curing process 8 is performed over laminated structure.

The UV exposed laminated structure, having phase separated polymer/liquid crystal composite 5 inside, is cut into segments. The perimeter of the cut segment is sealed using sealant to protect the polymer/liquid crystal composite 5 and thus the electronic blind panel 9 is fabricated.

FIG. 3( a) shows the side view of electronic blind panel. FIG. 3( b) shows the front view of electronic blind panel. FIG. 3( c) shows the cross sectional view of electronic blind panel. In FIG. 3( a) to FIG. 3( c) polymer/liquid crystal composite material 5 is sandwiched between 1st film substrate 1 and 2nd film substrate 2 and the perimeter is sealed using sealant to protect the polymer/liquid crystal composite 5. The polymer/liquid crystal composite 5 is milky white. The 2nd film substrate 2 has ITO layer 4A having width of 40 mm at the interval of 0.5 mm (layer without ITO 4B where space width is 0.5 mm). The length 10 of the electronic blind panel could be customized according to purpose. The width of the electronic blind 11 as shown in FIG. 3( b) is 600 mm however this width is not limited and it could be of custom length according to purpose.

FIG. 4( a) shows the schematic of an example of contact electrode for 1st substrate. FIG. 4( b) shows the schematic for contact electrode for individual segments of ITO patterned 2nd substrate. FIG. 4( c) shows the schematic of fabrication of electronic blind made from 1st film substrate with contact electrode and 2 nd film substrate with contact electrode for individual ITO layer segments.

In FIG. 4( a) copper foil contact electrode 12 is press laminated over offset are a of 1st film substrate having uniform layer transparent conductive ITO layer electrode on its one surface.

Similarly, as shown in FIG. 4( b) eight copper foil contact electrodes 13 (13A to 13H) are press laminated over offset area. FIG. 4( c) is the schematic of electronic blind with polymer/liquid crystal composite in milky white state, where copper foil contact electrode 12 of 1st film substrate and contact electrode 13 (13A to 13H) of 2nd film substrate of electronic blind panel 9 is made cross to each other.

FIG. 5( a) shows the schematic of an example of individual segment of electronic blind switched to clear transparent state on application of electric field. FIG. 5( b) shows the plurality of the segments of electronic blind switched to clear transparent state on application of electric field. FIG. 5( c) shows the schematic of an example of electronic blind when all the segments are switched to clear transparent state on application of electric field.

An ac electric field of 60 Hz and 30 V is applied across the composite layer through coupling the voltage source across contact electrodes 12 and an individual segment electrode 13A (out of 13A to 13H). The individual segment across 13A becomes transparent where as other segments remains milky white as shown in FIG. 5( a). Similarly, an electric field is applied across the composite layer through coupling the voltage source across contacting electrodes 12 and a plurality of electrode segments such as 13A to 13C.

The segments across 13A to 13C become transparent where as other segments remains milky white as shown in FIG. 5( b).

Next, an electric field is applied across the composite layer through coupling the voltage source across contacting electrodes 12 and an all the electrode segments 13A to 13H. As a result whole electronic blind becomes totally transparent.

Since, an electronic blind disclosed in this invention has one substrate's patterned electrode from one side of the substrate to the other side of substrate in line form voltage can be applied to individual segments. Thus, light control management is possible by controlling the transparency or opaque state of partial or over whole all area. Also, since one substrate has patterned electrode and another substrate has uniform electrode, there is no need to fine adjust the opposite facing electrodes to configure the electronic blind.

Since electronic blind as disclosed in the present invention light could be controlled over not only whole area but selective partial area also, the electronic blind could be used as for window of building and automobiles in place of existing blind. For example in Hospital, a patient can see the sky outside on desire by remote switching the upper segment of the electronic blind to clear state, furthermore for automotive application such as car or bus, one can enjoy the scenery outside without glare even in sunny day, while keeping ones privacy, by making half lower portion of rear side window opaque with no applied voltage.

Furthermore, while being in meeting room etc. one can control the electronic blind through remote control and could control it as of opening and closing of blind or curtain without approaching near by.

Furthermore, 1st film substrate has copper foil electrode across from 2nd film substrate that has connective electrodes over ITO layer in relay form. By applying the electric voltage across the corresponding ITO layer segments, individual segment or whole are can be controlled. 

1. An electronic blind that comprises a pair of substrates, polymer/liquid crystal composite material sandwiched between the pair of substrates, and a pair of electrodes formed on an opposing surface of the pair of substrates, one electrode of the pair of electrodes being patterned over one substrate in line form at intervals from one side to the other side of the substrate, other electrode of the pair of electrodes being formed over whole the surface of another substrate, the pair of substrates being film substrates selected from polyethylene terephthalate film or polyethylene naphthalate film.
 2. The electronic blind according to claim 1, wherein one electrode is patterned at interval of 0.2 mm or less.
 3. A method for manufacturing an electronic blind, which comprises a step of forming a pair of electrodes on an opposing surface of a pair of substrates and a step of sandwiching polymer/liquid crystal composite material between the pair of substrates, the step of forming a pair of electrodes on an opposing surface of a pair of substrates, which has a step of patterning plurality of electrodes over one substrate in line form at intervals from one side to the other side of the substrate, and a step of forming a single electrode over whole the surface of another substrate, the pair of substrates being film substrates selected from polyethylene terephthalate film or polyethylene naphthalate film.
 4. The method for manufacturing an electronic blind according to claim 3, wherein the film substrates unwind from a roll.
 5. The method for manufacturing an electronic blind according to claim 3, wherein the viscosity of liquid crystal material in the polymer/liquid crystal composite material is 50 to 250 mPa·s. 